Plush system

ABSTRACT

The plush figure has a variety of different from core rectangular prism shapes that can be interconnected such as by stitching. The plush figure has a foam core head with cutouts along corners of the foam core head. The foam core has rectangular sides with orthogonal features. Each of the orthogonal edges is preferably notched with a cutout. The cutout is an indentation along the edge of the foam core to provide a relief for receiving a fabric stitching flap. Each of these cutouts is sized and shaped to receive a fabric stitching flap formed by a fabric plush cover that fits over the core portion.

FIELD OF THE INVENTION

The present invention is in the field of plush apparatus.

DISCUSSION OF RELATED ART

Foam plush toys have been popular among children and adults of all ages for years. Typically, plush toys are composed of an outer plush shell mad of fabric usually sewn together around a cavity stuffing filled with cotton or other soft material. These plush toys are usually held together with nothing more than a few stitches, which can easily rip and cause the plush to lose its shape or even have its contents spill out. Because traditional plush toys are held together with nothing more than a few stitches, the durability of the toy can be lacking with the constant handling of the plush toy.

A variety of different plush toys have been created in the prior art, but inventors continue to strive to create foam plush that are sturdier and more resilient to tear. As an improvement to traditional plush toys, a variety of inventions have experimented with the inside contents of the toy. For example, a plush toy as described in U.S. Pat. No. 9,216,360 filed Dec. 22, 2015 to Mr. Hilton, the disclosure of which is incorporated herein by reference, provides a plush filled with a shape conforming substance, such as a mass of polystyrene beads.

Some plush toys are also capable of emitting sound when squeezed. For example, Morley and Garbos shows in U.S. Pat. No. 9,573,070, filed Mar. 21, 2017 a mechanical plush toy that emits responsive actions when the toy is compressed. By utilizing several foam sheets found within the plush cavity, the inner electrical mechanisms are protected. Likewise, in U.S. Pat. No. 9,345,234 filed May 24, 2016 by Curry and Ritchey discloses an animal toy that has a hollow thin-walled elastomer core that provides pliability.

SUMMARY OF THE INVENTION

A plush apparatus has a foam core with an edge. A cutout is formed on the foam core. The cutout is formed as a groove along the edge of the foam core. A fabric cover is fitted over the foam core. A fabric corner is formed on the fabric cover. The fabric corner is formed as an edge of the fabric cover. A flap extends inwardly from the fabric corner of the fabric cover. The flap has an inside flap edge that lodges inside the cutout. The cutout can be formed with a pair of orthogonal surfaces, namely a first cutout surface orthogonal to a foam core second cutout surface.

The plush apparatus may also have a foam core second surface. The foam core first cutout surface is parallel to the foam core second surface. The foam core second cutout surface is parallel to a foam core first surface. The plush apparatus also has a foam core first surface parallel to the fabric shell first surface; and a foam core second surface parallel to the fabric shell second surface. The fabric corner can be stitched together such that a first flap sheet is stitched to a second flap sheet. A first flap sheet and a second flap sheet extend inwardly from the fabric corner. The first flap sheet is an extension of a fabric shell first surface and the second flap sheet is an extension of a fabric shell second surface. The first flap sheet and the second flap sheet join at an inside flap edge. The cutout is formed with a pair of orthogonal surfaces, namely a first cutout surface orthogonal to a foam core second cutout surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of present invention.

FIG. 2 is a rear view of the present invention.

FIG. 3 is a front view of the present invention in multiple leg configuration.

FIG. 4 is a cross-section of the present invention.

FIG. 5 is a top view diagram showing assembly of the fabric shell over the foam core head.

The following call out list of elements can be a useful guide in reference to the elements of the drawings.

 21 Foam Core Head  22 Foam Core Head Front Right Corner Cut Out  23 Foam Core Head Front Left Corner Cut Out  24 Foam Core Head Rear Left Corner Cut Out  25 Foam Core Head Rear Right Corner Cut Out  31 Foam Core Body  32 Foam Core Body Front Right Corner Cutout  33 Foam Core Body Front Left Corner Cut Out  34 Foam Core Body Rear Left Corner Cut Out  35 Foam Core Body Rear Right Corner Cut Out  36 Foam Core Body Cavity  37 Foam Core Body Front Face  38 Foam Core Body Rear Face 132 Foam Core Body Top Face 133 Foam Core Body Bottom Face 134 Foam Core Body Left Side Face 135 Foam Core Body Right Side Face  41 Right Leg  42 Left Leg  43 Front Left Leg  44 Front Right Leg  45 Rear Left Leg  46 Rear Right Leg  51 Foam Core  52 Foam Core Cut Out  53 Foam Core First Surface  54 Foam Core Second Surface  55 Foam Core First Cutout Surface  56 Foam Core Second Cutout Surface  57 Foam Core Inside Corner  61 Fabric Shell  62 Fabric Shell First Surface  63 Fabric Shell Second Surface  64 First Flap Sheet  65 Second Flap Sheet  66 Inside Flap Edge  67 Fabric Corner  68 Flap Stitching  71 First Stitched Edge  72 Second Stitched Edge  73 Third Stitched Edge  74 Fourth Stitched Edge  75 First Folded Edge  76 Second Folded Edge  77 Third Folded Edge  78 Fourth Folded Edge

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is an assembly for a plush figure system that contains several rectangular prim shapes that can be interconnected such as by stitching. The plush figure has a foam head with cutouts around the corners. The foam core has rectangular sides with orthogonal features. Each of these features is preferably notched with a cutout. The cutout is an indentation along the edge of the foam core to provide a relief for receiving a fabric stitching flap. The plush figure also has four foam legs with the same features. With a pair of foam legs on each side, the foam core is attached to the foam head. Each of these cutouts is sized and shaped to receive a fabric stitching flap formed by a fabric plush cover that fits over the core portion.

The plush figure has a variety of different from core rectangular prism shapes that can be interconnected such as by stitching. The plush figure has a foam core head 21 with cutouts along corners of the foam core head 21. The foam core has rectangular sides with orthogonal features. Each of the orthogonal edges is preferably notched with a cutout. The cutout is an indentation along the edge of the foam core to provide a relief for receiving a fabric stitching flap. For example, in the first figure and the second figure, the foam core head has a foam core had front right corner cutout 22, a foam core head front left corner cutout 23, a foam core head rear left corner cutout 24, and a foam core head rear right corner cutout 25. Each of these cutouts is sized and shaped to receive a fabric stitching flap formed by a fabric plush cover that fits over the core portion.

Similarly, the foam core body 31 has a foam core body front right corner cutout 32, foam core body front left corner cut out 33, foam core body rear left corner cut out 34, and foam core body rear right corner cut out 35. The foam core body can be made of expended polyurethane foam.

The foam core body 31 can have a rectangular front face 37 parallel to a rectangular rear face 38, and also have a rectangular foam core body left side face 134 parallel to a rectangular foam core body right side face 135. The foam core body 31 can have a rectangular top face 39 and a rectangular bottom face. The rectangular foam core body top face 132 would be connected to the foam core head 21 also, the rectangular foam core body bottom face 133 would be connected to the legs such as by stitching. The right leg 41 and the left leg 42 can be joined at an upper leg edge to the foam core body bottom face 133.

The plush figure can have four legs also, for example, a front left leg 43, a front right leg 44, a rear left leg 45, and a rear right leg 46. The legs also have a snuggly fitted cover over them.

In general, the foam core 51 has a foam core cutout 52. The foam core cutout 52 is formed at a junction between orthogonal services, namely the foam core first surface 53 and the foam core second surface 54. The foam core cutout 52 has a foam core inside corner 57 that retains an inside flap edge 66 of a fabric flap. The fabric shell 61 encapsulates the foam core 51 and includes a fabric Shell first surface 62 parallel to the foam core first surface 53, and includes a fabric shell second surface 63 parallel to the foam core second surface 54. The fabric shell first surface 62 joints to the fabric shell second surface 63 at a fabric corner 67.

The foam core first cutout surface 55 is preferably orthogonal to the foam core second cutout surface 56. The foam core first cutout surface 55 is preferably parallel to the foam core second surface 54 and the fabric shell second surface 63. The foam core second cutout surface 56 is preferably parallel to the foam core first surface 53 and the fabric shell first surface 52.

The inside flap edge 66 extends from the fabric corner 67. The fabric corner 67 is stitched together such that the first flap sheet 64 is stitched to the second flap sheet 65. The first flap sheet 64 and the second flap sheet 65 extend inwardly from the fabric corner 67. The first flap sheet 64 is an extension of the fabric shell first surface 62 and the second flap sheet 65 is an extension of the fabric shell second surface 63. The first flap sheet 64 and the second flap sheet 65 join at an inside flap edge 66. The flap stitching 68 is transverse to the first flap sheet 64 and the second flap sheet 65.

The fabric shell 61 when seen from above as in FIG. 5, appears as a cube. The fabric shell 61 has a fabric shell first surface 62 and a fabric shell second surface 63 that join at a fabric corner 67. By engaging the inside corner 57 of the foam core 51, the inside flap edge 66 retains the fabric corner 67 at a level of the foam core first surface 53 and at a level of the foam core second surface 54. The inside flap edge has a length such as the length of a hem.

From a top view as seen in FIG. 5, the flap stitching 68 provides a clean square fabric shell 61 having a variety of stitched edges and folded edges. For example, a first stitched edge 71, a second stitched edge 72, a third stitched edge 73, and a fourth stitched edge 74 can be parallel to each other and form for edges of a cuboid fabric shell 61 plush cover. Additionally, the four folded edges can be along the top of the cube shaped cover, namely a first folded edge 75, second folded edge 76, third folded edge 77, and a fourth folded edge 78. 

1. A plush apparatus comprising: a foam core having an edge; a cutout formed on the foam core, wherein the cutout is formed as a groove along the edge of the foam core; a fabric cover fitted over the foam core; a fabric corner formed on the fabric cover, wherein the fabric corner is formed as an edge of the fabric cover; a flap extending inwardly from the fabric corner of the fabric cover, wherein the flap has an inside flap edge that lodges inside the cutout.
 2. The plush apparatus of claim 1, wherein the cutout is formed with a pair of orthogonal surfaces, namely a first cutout surface orthogonal to a foam core second cutout surface.
 3. The plush apparatus of claim 2, further comprising: a foam core second surface, wherein the foam core first cutout surface is parallel to the foam core second surface, and wherein the foam core second cutout surface is parallel to a foam core first surface
 4. The plush apparatus of claim 2, further comprising: a foam core first surface parallel to the fabric shell first surface; and a foam core second surface parallel to the fabric shell second surface.
 5. The plush apparatus of claim 1, wherein the fabric corner is stitched together such that a first flap sheet is stitched to a second flap sheet.
 6. The plush apparatus of claim 1, wherein a first flap sheet and a second flap sheet extend inwardly from the fabric corner.
 7. The plush apparatus of claim 1, wherein a first flap sheet is an extension of a fabric shell first surface and a second flap sheet is an extension of a fabric shell second surface, wherein the first flap sheet and the second flap sheet join at an inside flap edge.
 8. The plush apparatus of claim 7, wherein the cutout is formed with a pair of orthogonal surfaces, namely a first cutout surface orthogonal to a foam core second cutout surface.
 9. The plush apparatus of claim 7, further comprising: a foam core second surface, wherein the foam core first cutout surface is parallel to the foam core second surface, and wherein the foam core second cutout surface is parallel to a foam core first surface.
 10. The plush apparatus of claim 7, further comprising: a foam core first surface parallel to the fabric shell first surface; and a foam core second surface parallel to the fabric shell second surface.
 11. The plush apparatus of claim 7, wherein the fabric corner is stitched together such that a first flap sheet is stitched to a second flap sheet.
 12. The plush apparatus of claim 7, wherein a first flap sheet and a second flap sheet extend inwardly from the fabric corner, wherein the first flap sheet and the second flap sheet form the inside flap edge that lodges inside the cutout.
 13. The plush apparatus of claim 12, wherein the cutout is formed with a pair of orthogonal surfaces, namely a first cutout surface orthogonal to a foam core second cutout surface.
 14. The plush apparatus of claim 12, further comprising: a foam core second surface, wherein the foam core first cutout surface is parallel to the foam core second surface, and wherein the foam core second cutout surface is parallel to a foam core first surface.
 15. The plush apparatus of claim 12, further comprising: a foam core first surface parallel to the fabric shell first surface; and a foam core second surface parallel to the fabric shell second surface.
 16. The plush apparatus of claim 12, wherein the fabric corner is stitched together such that a first flap sheet is stitched to a second flap sheet.
 17. The plush apparatus of claim 16, wherein the foam core is configured as a cube shaped foam core head.
 18. The plush apparatus of claim 16, wherein the foam core is configured as a cuboid shape foam core body.
 19. The plush apparatus of claim 16, wherein the foam core is configured as a leg. 